Vehicle seat trim attachment

ABSTRACT

A trim material attachment assembly for a seat includes a cushion having first and second sides and an aperture formed therethrough. A trim cover is provided for covering the first side of the seat cushion. A one-piece, integrally molded trim holder includes a central member disposed in the aperture of the cushion. The central member has first and second ends. A clip is formed at the first end of the central member and engaged with the trim cover to secure the holder to the trim cover. A leg is formed at the second end of the central member and is connected to the second end by a living hinge permitting the leg to move between an assembly position to allow the plate member to be inserted through the aperture, and a holding position to prevent the leg from being pulled through the aperture, thereby securing the trim cover to the cushion.

BACKGROUND OF THE INVENTION

This invention relates in general to vehicle seats and in particular to a trim attachment assembly and method of attaching a trim cover to a seat cushion.

Vehicle seats generally include a seat back and a seat cushion or bottom. The seat back is commonly pivotally attached to the seat bottom. Each of the seat back and the seat bottom includes a framework, a cushion or padding connected to the framework, and a trim cover for decoratively covering and protecting the cushion. Typically, the cushion is made of an expandable foam material and is molded to a desired shape. Examples of trim covers include leather, polymers, and fabric.

Various seat trim attachment assemblies are commonly used in the industry. One such type of attachment assembly is often referred to as a close out attachment wherein the attachment assembly is generally not readily visible and is commonly located along the underside of the seat back or bottom. Another type of attachment is referred to as a trench attachment wherein the attachment area is readily visible by the vehicle occupants. In this situation, such as in bucket-style seats, the trench attachment is employed along the areas where the raised o]bolsters meet the recessed central seating and back sections, thereby creating a valley or trench where the trim material is secured to avoid the appearance of loose fitting trim material. The trench is often located at seam lines, and thus the seam is drawn slightly into the foam cushion of the seat.

One known example of a trench style attachment is disclosed in U.S. Pat. No. 6,899,399 in which a plurality of clips or receiving members are molded at desired locations within the expandable foam cushion. The receiving members include resilient gripping tabs. A wedge strip is then attached to a seam of a trim cover. The foam cushion includes trenches formed therein generally at the seam locations. The wedge strip is pulled into the trench and the wedge strip is resiliently connected to the gripping tabs of the receiving member. Although this type of attachment has proven capable of providing an attachment, one of the disadvantages to this method is that it is often difficult to mold the plurality of receiving members accurately within the foam cushion.

Another type of a trench style attachment is disclosed in U.S. Pat. No. 4,609,226. In this method, the foam cushion is provided with trenches and apertures formed through the foam cushion at various locations along the length of the trench. Seams of the trim cover are sewn together. A plurality of flexible hanger members are then sewn to the seams of the trim cover. The hanger members are disposed in the apertures of the foam cushion. The other end of the flexible hanger members are sewn to securing plates which are inserted through the apertures and then moved to a position adjacent to and co planar with the bottom surface of the cushion so as to prevent the seam from being pulled up through the trench. The sewing attachment of the hanger members to the trim cover and the sewing attachment of the securing plates to the hanger members is a cumbersome and timely process.

SUMMARY OF THE INVENTION

A trim material attachment assembly for a seat includes a cushion having first and second sides and an aperture formed therethrough. A trim cover is provided for covering the first side of the seat cushion. A one-piece, integrally molded trim holder includes a central member disposed in the aperture of the cushion. The central member has first and second ends. A clip is formed at the first end of the central member and engaged with the trim cover to secure the holder to the trim cover. A leg is formed at the second end of the central member and is connected to the second end by a living hinge permitting the leg to move between an assembly position to allow the plate member to be inserted through the aperture, and a holding position to prevent the leg from being pulled through the aperture, thereby securing the trim cover to the cushion.

Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of seat assembly utilizing a trim attachment assembly in accordance with the present invention.

FIG. 2 is a cross-sectional view taken along lines 2-2 of FIG. 1 illustrating an trim attachment assembly.

FIG. 3 is a partial perspective view of a connector assembly used in the trim attachment assembly of FIG. 2.

FIG. 4 is a perspective view of a clip used in the trim attachment assembly of FIG. 2.

FIG. 5 is a cross-sectional view similar to FIG. 2 but illustrating a step in the method of using the trim attachment assembly.

FIG. 6 is a partial schematic cross-sectional view illustrating an initial step in the use of a tool assembly for assisting in installing the trim attachment assembly.

FIG. 7 is a partial schematic cross-sectional view illustrating a subsequent step in the use of the tool assembly of FIG. 6 for assisting the installation of the trim attachment assembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings, there is illustrated in FIG. 1 a seat, indicated generally at 10. The seat 10 generally includes a seat bottom 12 and a seat back 14. The seat 10 is shown having a bucket type configuration but it should be understood that the seat 10 can have any desired structure and/or appearance. The seat bottom 12 and the seat back 14 may be made in a similar manner and for ease of description, only the formation of the seat bottom 12 will be described in detail below but is should be understood that the same may be used in assembling the seat back 14.

The seat bottom 14 includes a framework (not shown) for supporting a foam cushion 20. The cushion 20 is preferably made of a foam material, such as an expandable polymer. The cushion has a first or upper surface 22 and a second or lower surface 24 facing downward towards the floor the vehicle in which the seat 10 is installed. The upper surface 22 and side portions of the seat bottom 14 are covered by a flexible trim cover 30. The trim cover 30 can be any suitable material for covering and protecting the upper surface 22. Examples of suitable material for the trim cover 30 include leather, vinyl or other polymers, cloth, and/or fabric. The trim cover 30 may be provided in separate sections which are sewn together to define seams 32 therebetween. In the embodiment shown in FIG. 1, the trim cover 30 includes a central section 34, a front section 35, and side bolster sections 36 defined by seams therebetween. As will be explained in detail below, a plurality of trim attachment assemblies 40 are used to attach the trim cover 30 to the cushion 20 in a manner so as to slightly draw the seams 32 inwardly into the cushion 20 to provide a pleasant overall appearance of the seat bottom 12. The cushion 20 includes channels or trenches 37 formed therein such that the seams 32 may be inserted therein. A plurality of apertures 39 are formed through the cushion 20 at locations within the trenches 37 at a spaced relationship with one another. As will be discussed below, the apertures 39 correspond with location of clips 44 which are inserted therethrough. For clarity, the width of the trenches 37 and the apertures 39 are shown enlarged but it should be understood that the trenches 37 and the apertures 39 may be much smaller and may be simply spread apart when needed since the cushion 20 is preferably made of a flexible foam material capable of such deformation.

As best shown in the example of a trim attachment in FIGS. 2 through 4, the trim attachment assembly 40 generally includes a hanging connector assembly 42 and a trim holder or clip 44. The trim holder or clip 44 is preferably a one-piece, integrally molded part. As shown in FIG. 2, the trim attachment assembly 40 is used to attach the central section 34 of the trim cover 30 and the side bolster section 36 of the trim cover 30 to the cushion 30. Edges of the central section 34 and the bolster section 36 are attached together by one or more sewing threads 38. The hanging connector assembly 42 includes a strip 50 which is attached to the edges of the central section 34 and the bolster section 36; such as by the threads 38. The strip 50 may be made of a flexible material, such as fabric or cloth, and may even be made of the same material as the trim cover 30. The strip 50 preferably extends along the length of the seam 32 joining the central section 34 and the bolster section 36. As shown in FIGS. 2 and 3, the strip 50 includes a lower edge 52 having bead 54 formed thereon and extending along the length of the edge 52. The bead 54 may be made of any suitable material, such as plastic and may be attached to the edge 52 by molding the bead 54 directly thereto. If desired, the bead 54 and/or the edge 52 of the strip 50 may have features such as holes (not shown) to facilitate the attachment 54 to the strip 50 wherein the molded material of the bead 54 flows through the holes. The bead 54 may any desirable cross-sectional shape, and as will be discussed below cooperates with a portion of the clip 44 to connect the two together. The strip 50 may further include apertures 58 formed therethrough and spaced along its length for receiving a portion of the clips 44 as will be discussed below.

The clip 44 generally includes a clip or hook portion 60, a central member 62, and a plate 64. In one embodiment, the hook portion 60, the central member 62, and the plate 64 are integrally formed from a common material, such as molded plastic. The clips 44 can be made individually, or formed from cutting portions of an extrusion having a cross-sectional profile as best shown in FIG. 4. The central member 62 is generally an elongated strip having a first end 66 and a second end 68. The hook portion 60 is connected to the first end 66. The plate 64 is connected to the second end 68 by a living hinge 70 to permit the plate 64 to pivot or rotate relative to the central member 62. The living hinge 70 can be any feature, such as a reduced thickness region, to permit bending there at.

The plate 64 includes a first leg 72 extending from the second end 68 of the central member 62 in a first direction, and a includes a second leg 74 extending from the second end 68 in a second direction opposite the first direction, the reason for which will be explained below. The plate 64 is movable between a holding position, as shown in FIGS. 2 or 3, and a assembly position, as shown in FIG. 5 wherein the second leg 74 is adjacent the central member 62.

The hook portion 60 is defined by an open loop structure having an opening 80. A free end 82 of the hook portion 60 preferably includes an outwardly extending lip 84 having an angled surface 86 in an angled relationship relative to the length of the central member 62. The lip 84 and angled surface 86 help guide the bead 54 and open up the hook portion 54 as it is inserted therein.

The operation and assembly of the trim attachment assembly 40 will now be described. The trim cover 30 is preferably provided above the upper surface 22 of the cushion 20 and with the hanging connector assembly 42 attached thereto such that there are connector assemblies 42 attached to the seams 32. A plurality of clips 44 are attached to the connector assemblies 42 at spaced relationships along the length of the connector assemblies 42. For example, three clips can be used along the seam 32 between the central section 34 and a side bolster section 36. To attach a clip 44, the free end 82 of the hook portion 60 is inserted through the aperture 58 of the strip 50 such that the bead 54 is trapped within the hook portion 60. The plate 64 is then pivoted from its holding position to its assembly position, as shown in FIG. 5. In the assembly position, the second leg 74 is positioned generally adjacent the central member 62. However, note that the second leg 74 need not contact the central member 62 or be exactly parallel with the central member 62. The clip 44 is then inserted through a respective aperture 39, as shown in FIG. 5, in a direction from the upper surface 22 towards the lower surface 24. The clip 44 is inserted until the plate 64 of the clip 44 extends past the lower surface 24. At this time, the plate 64 can then be moved from its assembly position to its holding position as shown in FIG. 2 adjacent and generally co-planar with the lower surface 24. It is preferred that the length of the legs 72 and 74 are larger than with of the aperture 39 such that clip 44 is prevented from being pulled upward through the aperture 39 once the plate is moved to its holding position. As the clip 44 is pulled downward through the aperture 39, the hook portion 60 will pull the strip 50 into the trench 37. Note that during this operation, the foam material of the cushion 20 may be compressed as needed until the trim attachment assembly 40 is positioned as shown in FIG. 2. The length and dimensions of the clip 22 and the strip 50 are designed to create a desired draw of the seam 32 within the trench 37.

While the clip 44 has been shown and described as having a living hinge 70 for folding the plate 64 to its assembly position, it should be appreciated that the living hinge may be formed differently such that the clip 44 is permitted to rotate relative to the strip 50 wherein the clip 44 is inserted in an unfolded manner through a larger aperture 39 (such as an elongated slot) and then rotated relative to the cushion to prevent the clip 44 form being pulled back through the aperture.

There is illustrated in FIGS. 6 and 7 a tool assembly 100 which may be used for assistance in installing the trim attachment assembly 40 and trim cover 30 onto the cushion 20. The cushion 20 is preferably generally fixed relative to a tool housing 102 of the tool assembly 100. The tool housing 102 includes a ramped surface 103. The tool assembly 100 includes a plurality of elongated arms 104 which are movable relative to the cushion 20 and the tool housing 102. For simplicity, only the operation of one of the arms 104 will be described but it should be understood that the tool assembly 100 may include a plurality of arms 104 corresponding to the number of clips 44 to be installed on the seat 10. The arm 104 is movable through the aperture 39 of the cushion 20. The tool assembly 100 also includes a clip holder 108 which is pivotally mounted on the arm 104 at a pivot point 110. The clip holder 108 may include a main body 112 and a pair of end detents 114 having slightly curved portions such that a clip 44 may be temporarily and resiliently retained on the clip holder 108. The clip holder 108 includes a slot 120 which accommodates receiving an extension 122 of the arm 104, the reason for which will be explained below.

In operation, the tool assembly 100 is positioned such that the arm 104 extends through the aperture 39 of the cushion 20, as shown in FIG. 6. The trim cover 30 is preferably provided above the upper surface 22 of the cushion 20 and with the hanging connector assemblies 42 attached thereto such that there are connector assemblies 42 attached to the seams 32. A plurality of clips 44 are attached to the connector assemblies 42 at spaced relationships along the length of the connector assemblies 42. The clips 44 are then attached to the holding guides 108. Preferably, each of the apertures 39 for the respective clips 44 includes an arm 104 extending therethrough. In one embodiment, the holding guides 108 include detents 114 on the outer edges thereof for resiliently snap fitting the clips 44 onto the holding guides 108, as shown in FIG. 6, however it should be understood that the clips 44 may be temporarily attached to the holding guides 108 by any suitable manner. It is also desirable to spring bias the holding guides 108 in their generally positions as viewing FIG. 6. Thus, the tool assembly 10 can include a spring member (not shown) for biasing the holding guide 104 in a generally vertical direction, as viewing FIG. 6, such that it can readily be inserted through the aperture 39. Once the clips 44 are installed on the holding guides 108, the arms 104 are withdrawn (lowered as viewing FIGS. 6 and 7) through the apertures 39, thereby pulling in the strip 50 and the edges of the trim cover 30 towards the trenches 37. As shown in FIG. 7, when the arm 104 has moved a sufficient distance downward and the clip 44 is below the aperture 39, the holding guide 108 contacts the ramped surface 103. Further downward movement of the arm 104 will cause the holding guide 108 to slide along the ramped surface 103, thereby rotating the holding guide 108 and the clip 44. Rotation of the holding guide 108 causes the extension 122 of the arm 104 to move through the slot 122 in the holding guide 108, as shown in FIG. 7, thereby pushing the clip 44 automatically upwardly releasing the clip 44 from the holding guide 108. Once the clip 44 is released from the holding guide 108, the clip 44 is free to move upward and to move the plate 64 to its holding position against the lower surface 24 of the cushion, as shown in FIG. 2. Note that due to the compressibility of the cushion 20, the clip 44 and strip 50 can be pulled down to manipulate the position of the plate 64, and the cushion 20 will readily uncompress to move the clip 44 upward to its final position.

In accordance with the provisions of the patent statutes, the principle and mode of operation of this invention have been explained and illustrated in its preferred embodiments. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope. 

1. A trim material attachment assembly for a seat comprising: a cushion having first and second sides and an aperture formed therethrough; a trim cover for covering said first side of said seat cushion; and a one-piece, integrally molded trim holder including: a central member disposed in said aperture of said cushion, said central member having first and second ends; a clip formed at said first end of said central member and engaged with said trim cover to secure said holder to said trim cover; and a leg formed at said second end of said central member and connected to said second end by a living hinge permitting said leg to move between an assembly position to allow said leg to be inserted through said aperture, and a holding position to prevent said leg from being pulled through said aperture, thereby securing said trim cover to said cushion.
 2. The assembly of claim 1, wherein in the assembly position, the leg is positioned adjacent the central member, and wherein in the holding position, the leg is adjacent the second side of the seat cushion.
 3. The assembly of claim 1, wherein said trim cover includes a bead attached thereto, and wherein said trim cover includes a trim strip extending therefrom, said bead being attached to said trim strip, and wherein said clip resiliently engages with said bead.
 4. The assembly of claim 1, wherein said leg extends from said second end of said central member in a first direction, and wherein a second leg extends from said second end of said central member in a second direction opposite the first direction.
 5. The assembly of claim 1, wherein said clip is in the form of a hook.
 6. The assembly of claim 5, wherein said clip is in the form of an open ended hook.
 7. The assembly of claim 1, wherein said central member is an elongated strip.
 8. The assembly of claim 1, wherein said clip is made of a plastic material.
 9. The assembly of claim 1, wherein said trim cover includes a trim strip extending therefrom, and wherein said bead is attached to said trim strip.
 10. The assembly of claim 9, wherein said bead is molded onto said trim strip.
 11. The assembly of claim 9, wherein said trim strip is made of a flexible material.
 12. The assembly of claim 11, wherein said trim cover defines a seam, and wherein said trim strip is attached to said trim cover at said seam.
 13. The assembly of claim 9, wherein said trim strip is disposed in a formed in said first side of said cushion.
 14. The assembly of claim 9, wherein said trim strip includes an opening therein adjacent said bead, and wherein said hook portion is inserted through said opening.
 15. A method of attaching trim cover to a seat cushion comprising the steps of: a. providing a cushion having first and second sides and an aperture formed therethrough; b. providing a trim cover; and c. providing a one piece, integrally formed trim holder including: a central member disposed in the aperture of the cushion, the central member having first and second ends; a clip formed at the first end of the central member; and a leg formed at the second end of the central member and connected to the second end by a living hinge; d. attaching the clip to the trim cover; e. pivoting the leg to an assembly position adjacent the central member; f. inserting the leg through the aperture of the cushion; g. pivoting the leg to an assembly position adjacent the second side of the seat cushion, thereby preventing the trim holder from being pulled through the aperture, thereby attaching the trim cover to the seat cushion.
 16. The method of claim 15 further providing an installation tool including: a holding guide for temporarily holding the trim holder; an arm movably mounted relative to the seat cushion, wherein the holding guide is pivotally mounted on the arm; and wherein prior to step (f) the arm and the holding guide are extended through the aperture of the cushion such that the holding guide is spaced from the first side of the cushion, and wherein the clip is resiliently, temporarily attached to the holding guide, and wherein in step (e), the holding guide is moved to a position such that the leg is in its assembly position, and wherein in step (f) the arm is moved through the aperture, and wherein in step (g) the holding guide is rotated to move the leg into its holding position, and subsequently the trim holder is detached from the holding guide.
 17. The method of claim 16, wherein the installation tool further includes a fixture having a ramped surface facing the second side of the cushion, and wherein in step (g), the holding guide slides along the ramped surface thereby rotating the holding guide. 